Pallet with internal frame

ABSTRACT

Disclosed herein is a pallet that includes a top deck and a support section. The top deck includes a first frame portion and an encasement encasing the first frame portion. The support section includes a second frame portion connected to the first frame portion of the top deck.

PRIORITY CLAIM

This application claims priority to and benefit of U.S. Provisional Application 63/297,168, filed on Jan. 6, 2022, which is hereby incorporated by reference in its entirety, including but not limited to those portions that specifically appear hereinafter, the incorporation by reference being made with the following exception: In the event that any portion of the above-referenced applications are inconsistent with this application, this application supersedes said portion of said above-referenced applications.

TECHNICAL FIELD

This disclosure relates generally to a pallet that includes a top deck and a support section. The top deck includes a first frame portion and an encasement encasing the first frame portion. The support section includes a second frame portion connected to the first frame portion of the top deck.

BACKGROUND

The skid, a precursor to the pallet, has been used for ages and is believed to be first used in Ancient Egypt and Ancient Mesopotamia. Skids were used to transport heavy objects and may have been used to construct the pyramids of Giza. Constructed of wood, skids include a platform that is undergirded with runners, making dragging by man or by animal possible. Unlike skids, a pallet, that includes both a top and a bottom platform, became prevalent after the invention of the forklift in the 1920s. Nevertheless, the terms pallets and skids are generally used in modern convention to refer to the same object. Because pallets are reasonably low cost, lightweight, and durable as well as being extremely convenient to use with a forklift, pallets are the standard for transporting large, heavy, or awkward items. As a result, pallet usage has become ubiquitous in the transportation industry.

Pallets are generally categorized in four different ways: fork entry point, decking, design, and construction material. These different categories highlight different functions and advantages of different pallets. First, the fork entry point may include either a two-way entry point or a four-way entry point. This indicates openings in the pallet that allow a fork to be positioned under the pallet which is accessible from two or four sides of the pallet. A four-way entry point is more accessible but is structurally weaker than a two-way entry point. Second, in the decking category, there is usually a solid deck or an open deck. An open deck means that on the top deck there are spaces between the deck boards and a closed deck means there is little or no spacing between the deck boards. Third, pallets categorized by design usually focus on the spacing structure that attaches the bottom deck to the lower deck. This attachment is usually done by stringers or blocks. The stringers and blocks create space to allow entry of forks into openings in the pallet. Different pallets are identified based on where the support is allocated. Finally, pallets can be categorized by the material used in their fabrication. Pallets, conventionally, can be made of wood, metal, plastic, and compressed paper (cardboard).

Some of the common issues with pallets are their short lifespan such that most pallets end up in landfills. Further, pallets have been known to carry bacteria such as E Coli, Salmonella, and Listeria. In addition to bacteria, pallets have been known to carry invasive species, insects, and other toxic chemicals. Many craft or repurposing ideas have kept pallets out of the landfill but unfortunately, most pallets used in craft or repurposing projects could still have been used in the shipping industry. As a result, more pallets are produced because of the removal of pallets for craft or repurposing projects, and more pallets ultimately end up in the landfill. Furthermore, using pallets in crafts may further facilitate the spread of harmful bacteria and dangerous chemicals. To help combat the spread of harmful bacteria and dangerous chemicals, wood alternative materials that are less porous are used to make pallets. One problem with wood alternatives is that some of the manufacturing processes used to make these pallets may be more harmful to the environment than just using wood. Furthermore, many of these pallets are made from a single material and only take advantage of the properties of that single material.

It is the object of this disclosure is to provide a pallet that uses a skeleton and an encapsulating material that takes advantage of the strength and durability of both the skeleton and the encapsulating material. With increased strength and durability, it aims to extend the life and strength of the pallet.

SUMMARY

This disclosure relates generally to a pallet that includes a top deck having an encased first frame portion. The pallet also includes a support deck having an encased second frame portion.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive implementations of the present disclosure are described with reference to the following figures, wherein similar or like reference numerals refer to similar or like parts throughout the various views unless otherwise specified. The advantages of the present disclosure will become better understood with regard to the following description and accompanying drawings:

FIG. 1 illustrates a transparent perspective view of a pallet with an encased frame.

FIG. 2 illustrates an exploded perspective view of a pallet with an encased frame.

FIG. 3 illustrates a cross-sectional view of a pallet with an encased frame connected and disconnected to a base frame.

FIG. 4 illustrates a perspective view of an alternative block pallet with an encased frame.

FIG. 5 illustrates a bottom perspective view of an alternative pallet with runners and an encased frame.

DETAILED DESCRIPTION

In the following description, for purposes of explanation and not limitation, specific techniques and embodiments are set forth, such as particular techniques and configurations, in order to provide a thorough understanding of the device disclosed herein. While the techniques and embodiments will primarily be described in context with the accompanying drawings, those skilled in the art will further appreciate that the techniques and embodiments may also be practiced in other similar methods.

Reference will now be made in detail to the exemplary embodiments, examples of which are illustrated in the accompanying drawings. Wherever possible, the same or similar reference numbers are used throughout the drawings to refer to the same or similar parts. It is further noted that elements disclosed with respect to particular embodiments are not restricted to only those embodiments in which they are described. For example, an element described in reference to one embodiment or figure may be alternatively included in another embodiment or figure regardless of whether or not those elements are shown or described in another embodiment or figure. In other words, elements in the figures may be interchangeable between various embodiments disclosed herein, whether shown or not.

Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the recited claims.

FIG. 1 illustrates a transparent perspective view of pallet 100 with an encased frame 150 with encasement 145. Pallet 100 may include one or more of top deck 105, bottom deck 110, and support section 115. Top deck 105, bottom deck 110, and support section 115 may include a portion of frame 150. Further, frame 150 may be encased by encasement 145 which may encase all or a portion of frame 150. Frame 150 may include one or more of the following natural, synthetic, or recycled wood, metal (i.e. aluminum, and aluminum alloys steel and steel alloys, iron, and iron alloys), fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics (i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers including, for example, polyoxymethylene.

Top deck 105, which may be either an open or a closed deck, may further include, as part of frame 150, one or more joists 120A-I and one or more beams 125A-C. The term open deck means that top deck 105 includes openings or apertures which extend through the deck from the outside of the deck to a middle portion of a pallet. The term closed deck means deck 105 contains no openings or apertures while the term deck refers to either an open deck or a closed deck inclusively. Joists 120A-I may extend in a first direction and beams 125A-C may extend in a second direction. The second direction may be substantially perpendicular to the first direction. Substantially perpendicular, in this instance may mean plus or minus 10 degrees. Joists 120A-I and beams 125A-C may or may not be the same length, size, shape, or material.

Pallet 100 may further include bottom deck 110. Bottom deck 110 may include deck boards 135A-C and 140A-C. Deck boards 135A-C may extend in a first direction and deck boards 140A-C may extend in a second direction. The second direction may be substantially perpendicular to the first direction. Substantially perpendicular, in this instance means plus or minus 10 degrees. Deck boards 135A-C may or may not be the same length, size, shape, or material as deck boards 140A-C. Furthermore, deck boards 135A-C and 140A-C may further include one or more of frame 150 and encasement 145.

Top deck 105 may attach to bottom deck 110 by support section 115. Support section 115 may include a portion of frame 150 namely columns 130A-I. Columns 130A-I may attach top deck 105 by attaching to one or more of joists 120A-I and beams 125A-C. Alternatively, columns 130A-I may attach to encasement 145 of top deck 105. Columns 130A-I may further attach bottom deck 110 by attaching to one or more deck boards 135A-C and 140A-C, the material of the frame 150, and the material of encasement 145. Further, columns 130A-I may be encased by encasement 145. Columns 130A-I may be included in blocks and blocks may be used in support section 115. In an alternative embodiment, columns 130A-I may be combined to form one or more stringers. Wherein the stringers may include two outside stringers and one or more center stringers.

Encasement 145 may be comprised of one or more of a variety of materials, for example, natural, synthetic, or recycled wood, metal, fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics (i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers.

Different types of encasements 145 may be used in different areas of pallet 100. For example, joists 120A-I and beams 125A-C may be encased with styrene-Butadiene rubber while columns 130A-I may be encased with polyethylene and bottom deck 110 may be encased in synthetic wood. Further, the amount of encasement 145 may vary in different parts of pallet 100. For example, encasement 145 around columns 130A-I may be thicker than encasement 145 around joists 120A-I. Further, the thickness of encasement 145 around columns 130A-I and joists 120A-I may be thicker than encasement 145 around bottom deck 110. In one embodiment, top deck 105, bottom deck 110, joists 120A-I, beams 125A-C, and all other elements of pallet 100 may be encased in rubber, including rubber made substantially from tires.

FIG. 2 illustrates an exploded perspective view of pallet 200 with encased frame 250 with encasement 245. Pallet 200 may include one or more of top deck 205, bottom deck 210, and support section 215. One or more of top deck 205, bottom deck 210, and support section 215 may include a portion of frame 250. Further, frame 250 may be encased by encasement 245 which may encase all or a portion of frame 250.

Frame 250 may include one or more of the following natural, synthetic, or recycled wood, metal (i.e. aluminum, and aluminum alloys steel and steel alloys, iron, and iron alloys), fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics (i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers including, for example, polyoxymethylene.

Top deck 205, being either an open or a closed deck, may further include, as part of frame 250, one or more joists 220A-I and one or more beams 225A-C. Joists 220A-I may extend in a first direction and beams 225A-C may extend in a second direction. The second direction may be substantially perpendicular to the first direction. Substantially perpendicular, in this instance means plus or minus 10 degrees. Joists 220A-I and beams 225A-C may or may not be the same length, size, shape, or material.

Pallet 200 may further include bottom deck 210. Bottom deck 210 may include deck boards 235A-C and 240A-C. Deck boards 235A-C may extend in a first direction and deck boards 240A-C may extend in a second direction. The second direction may be substantially perpendicular to the first direction. Substantially perpendicular, in this instance means plus or minus 10 degrees. Deck boards 235A-C may or may not be the same length, size, shape, or material as deck boards 240A-C. Furthermore, deck boards 235A-C and 240A-C may further include one or more of frame 250 and encasement 245.

Top deck 205 may attach to bottom deck 210 by support section 215. Support section 215 may include a portion of frame 250 namely columns 230A-I. Columns 230A-I may attach top deck 205 by attaching to one or more of joists 220A-I and beams 225A-C. Columns 230A-I may further attach one or more deck boards 235A-C and 240A-C Material of the frame 250 and material of encasement 245. Further columns 230A-I may be encased by encasement 245. Columns 230A-I may be included in blocks and blocks may be used in support section 215. In an alternative embodiment, in support section 215 columns 230A-I may be combined to form one or more stringer. Wherein the stringers may include one or more outside stringers and one or more center stringers. Stringers and blocks may be combined in support section 215.

Encasement 245 may be comprised of one or more of a variety of materials, for example, natural, synthetic, or recycled wood, metal, fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers including, for example, polyoxymethylene.

Different types of encasements 245 may be used in different areas of pallet 200. For example, joists 220A-I and beams 225A-C may be encased with styrene-Butadiene rubber while the columns 230A-I may be encased with polyethylene and bottom deck 210 may be encased in synthetic wood. Further, the amount of encasement 245 may vary in different parts of pallet 200. For example, the encasement 245 around columns 230A-I may be thicker than the encasement 245 around joists 220A-I. Further, the thickness of encasement 245 around columns 230A-I and joists 220A-I may be thicker than encasement 245 around bottom deck 210. In one embodiment, pallet 200 may be encased in rubber, including rubber made substantially from tires.

FIG. 3 illustrates a cross-sectional view of pallet 300 with encased frame 340. Pallet 300 includes top deck 305, bottom deck 310, and support level 315. Each level, top deck 305, bottom deck 310, and support level 315 may include a portion of frame 340. Top deck 305, being either an open or a closed deck, may include joist 320 as a portion of frame 340. Further, these joists may be encased by encasement 345. Support level 315 may include columns 330 A-C as a portion of frame 340. Columns 330A-C may also be encased in encasement 345. Bottom deck 310 may include beam 335 such that bottom deck 310 includes beam 335, as part of frame 340 which is encased by encasement 345. Beam 335 may also connect to joist 325A-C. Beam 335 may extend in the first direction and joists 325 A-C may extend in a second direction. Accordingly, beam 335 may extend in a direction that is substantially perpendicular to joists 325A-C. Substantially in this instance means plus or minus 10 degrees. Columns 330A-B may be connected to beam 335. Column 330C may be disconnected from beam 335. In an alternative pallet 300, columns 330A-C may all be disconnected or connected to beam 335.

Frame 340 may include one or more of the following natural, synthetic, or recycled wood, metal (i.e. aluminum, and aluminum alloys steel and steel alloys, iron, and iron alloys), fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics (i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers including, for example, polyoxymethylene.

Encasement 345 may be comprised of one or more of a variety of materials, for example, natural, synthetic, or recycled wood, metal, fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics (i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers including, for example, polyoxymethylene.

Different types of encasements 345 may be used in different areas of pallet 300. For example, joist 320 may be encased with styrene-Butadiene rubber while columns 330A-C may be encased with polyethylene, and beam 335 may be encased in synthetic wood. Further, the amount of encasement 345 may vary in different parts of pallet 300. For example, the encasement 345 around columns 330A-C may be thicker than the encasement 345 around joist 320. Further, the thickness of encasement 345 around columns 330A-C and joist 320 may be thicker than encasement 345 around beam 335.

FIG. 4 shows a perspective view of an alternative of block pallet 400 with an encased frame 440 without a bottom deck. Pallet 400 may include top deck 405, bottom deck 110 as depicted in FIG. 1 ), and support section 415. One or more of top deck 405 and support section 415 may include a portion of frame 440. Frame 440 may include one or more of the following natural, synthetic, or recycled wood, metal (i.e. aluminum, and aluminum alloys steel and steel alloys, iron, and iron alloys), fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics (i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers including, for example, polyoxymethylene.

Further, frame 440 may be encased by encasement 435 which may encase all or a portion of frame 440. Top deck 405, being either an open or a closed deck, may further include, as part of frame 440, one or more joists 420A-C and one or more beams 425A-C. Joists 420A-C may extend in a first direction and beams 425A-C may extend in a second direction. The second direction may be substantially perpendicular to the first direction. Substantially perpendicular, in this instance means plus or minus 10 degrees. Joists 420A-C and beams 425A-C may or may not be the same length, size, shape, or material. Support section 415 may include a portion of frame 440 namely columns 430A-I. Columns 430A-E may attach top deck 405 by attaching to one or more of joists 420A-C and beams 425A-C. Further columns 430A-E may be encased by encasement 435. In an alternative embodiment, columns 430A-E may be combined to form one or more stringers. Wherein the stringers may include one or more outside stringers and one or more center stringers.

Encasement 435 may be comprised of one or more of a variety of materials, for example, natural, synthetic, or recycled wood, metal, fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics (i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers including, for example, polyoxymethylene. Different types of encasements 435 may be used in different areas of pallet 400. For example, joists 420A-C may be encased with styrene-Butadiene rubber while columns 430A-E may be encased in glass-reinforced plastic. Further, the amount of encasement 435 may vary in different parts of pallet 400. For example, the encasement 435 around columns 430A-E may be thicker than the encasement 435 around joists 420A-C.

Columns 430A-E may be included in blocks and blocks may be used in support section 415. In an alternative embodiment, columns 430A-E may be combined to form one or more runners which extend between two adjacent corners or opposing sides of pallet 400, as will be discussed in more detail below with respect to FIG. 5 . Runners may include one or more outside runners and one or more center, runners.

FIG. 5 illustrates a bottom perspective view of pallet 500 with runners 510A-C and an encased frame 540. Pallet 500 may top deck 505, columns 515A-I, and runners 510A-C. Top deck 505, may be a closed deck as depicted or an open deck Columns 515A-I may connect one or more of joists 520A-C or beams 525A-C. Joists 520A-C and beams 525A-C may be located in top deck 505 and may make up a portion of frame 540. Opposite one or more of beams 525A-C, pallet 500 may include bottom stringer support 530 as part of frame 540.

Frame 540 may include one or more of the following natural, synthetic, or recycled wood, metal (i.e. aluminum, and aluminum alloys steel and steel alloys, iron, and iron alloys), fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics (i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers including, for example, polyoxymethylene.

Runners 510A-C may also include one or more sloped sides. In an alternative embodiment, a stringer may be formed with a solid stringer that may run perpendicular to joists 520A-C. The top deck 505 may be a closed deck as depicted or an open deck. Top deck 505 may further be encased by encasement 535. Encasement 535 may be comprised of one or more of a variety of materials, for example, natural, synthetic, or recycled wood, metal, fabric, rubber (i.e., neoprene, silicone, nitrile, EPDM, Butadiene, Styrene, Styrene-Butadiene (“SBR”) Butyl Rubber, Fluorosilicone), plastics (i.e., nylons, acrylics, glass-reinforced plastics, PVC, UPVC, polyethylene high density or low density, polypropylene, polycarbonate, Bakelite, epoxy resins, melamine, and polymers including, for example, polyoxymethylene. Different types of encasements 535 may be used in different areas of pallet 500. For example, joists 520A-C may be encased with styrene-Butadiene rubber while the runners 510A-C may be encased in low-density polypropylene. Further, the amount of encasement 535 may vary in different parts of pallet 500. For example, the encasement 535 around runners 510A-C may be thicker than the encasement 535 around joists 520A-C. Pallet 500 may include a closed top deck 505 as depicted. Alternatively, top deck 505 may be an open deck 505. Also, in an alternative embodiment pallet 500 may include bottom deck 110 as depicted in FIG. 1 .

The foregoing description has been presented for purposes of illustration. It is not exhaustive and does not limit the invention to the precise forms or embodiments disclosed. Modifications and adaptations will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed embodiments. 

What is claimed is:
 1. A pallet comprising: a top deck comprising: a first frame portion, an encasement encasing the first frame portion; and a support section comprising: a second frame portion connected to the first frame portion of the top deck.
 2. The pallet of claim 1 wherein the first frame portion further comprises: one or more beams.
 3. The pallet of claim 1, wherein the first frame portion further comprises: one or more joists.
 4. The pallet of claim 1, wherein the second frame portion further comprises: one or more columns.
 5. The pallet of claim 1, wherein the second frame portion is encased with an encasement.
 6. The pallet of claim 6, wherein the encasement encasing the first frame portion comprises the same material as the encasement encasing the second frame portion.
 7. The pallet of claim 6, wherein the encasement encasing the first frame portion comprises one or more materials different from the encasement encasing the second frame portion.
 8. The pallet of claim 6, wherein the encased second frame portion forms one or more runners.
 9. The pallet of claim 8, wherein the encasement of one of the one or more runners forms an angle, the wider portion being positioned near the first frame portion.
 10. The pallet of claim 1, wherein the encasement further comprises: recycled material.
 11. The pallet of claim 1, wherein the encasement further comprises: synthetic rubber.
 12. The pallet of claim 1, wherein the encasement further comprises: natural rubber
 13. The pallet of claim 1, wherein the encasement further comprises: natural and synthetic rubber.
 14. The pallet of claim 1 wherein the pallet further comprises: a bottom deck comprising: a third frame portion.
 15. The pallet of claim 14, wherein the third frame portion is connected to the second frame portion.
 16. The pallet of claim 14, wherein the third frame portion further comprises: one or more deck boards.
 17. The pallet of claim 14, wherein the third frame portion further comprises: one or more bottom stringer supports.
 18. The pallet of claim 14, wherein the third frame portion is encased with encasement.
 19. The pallet of claim 14, wherein the encasement encasing the third frame portion comprises the same material as the encasement encasing the second frame portion.
 20. The pallet of claim 14, wherein the encasement encasing the third frame portion comprises one or more materials different from the encasement encasing the second frame portion. 